Channel shaped metal shim for correcting edgewise deviation in crooked framing lumber

ABSTRACT

A channel shaped metal shim for correcting edgewise deviation along the cupped edge of crooked framing lumber, the channel shaped metal shim comprises a web width ≧ the thickness of the cupped edge, and a first flange and second flange having a flange depth &lt;½ the face depth of the crooked framing member so that the first flange and second flange can be fixed to the crooked framing member without contacting utility service extending through the frame member.

BACKGROUND

The present invention is directed to a channel shaped metal shim used to correct deviation from a true or plane surface in wood framing, for example studs, joists, rafters and the like to provide a restored plane surface. Wood framing systems are frequently troubled by warping that occurs after the framework is completed. As framing lumber dries, it shrinks and undergoes stresses that cause wood members to warp, bow, cup, twist and check. Warped framing studs produce unattractive non-planer wall surfaces that are troublesome because the undulating surface can cause gaps between the wall finished work such as cabinetry, countertops, backsplashes, appliances, and trim. The non-planer wall surface is also problematic in tiled wall surfaces. Similarly, warped joists can cause rising or dipping in floor and ceiling surfaces, the dips and/or rises creating problems in tiled flooring, and warped rafters produce sagging roof lines that may retard water shedding.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes certain problems encountered with warped wood framing by providing a channel shaped metal shim that corrects deviation from a true or plane edge or end surface in crooked wood framing.

In one variation of the preferred embodiment, the channel shaped metal shim includes a web that extends between two flanges that are spaced apart at a distance equal to or greater than the plane edge or end surface width of the crooked frame member so that the flanges can clasp the face surface of the frame member, each flange having a flange length less that one half the depth of the face so that the flanges do not contact electrical wiring or plumbing lines that pass through the crooked framing.

In another variation, the flange length is 13/16 inches or greater.

In another variation, the flanges include a plurality of apertures for receiving fasteners that fix the flanges to the face.

In another variation, the flanges include a plurality of punched fastener tabs for fixing the flanges to the face.

As used herein, the term “crook” or “crooked” refers to framing lumber that has edgewise deviation from a straight line extending from end to end of the lumber.

The term “crown” or “crowned” refers to the convex edge or end surface of crooked lumber.

The term “cup” or “cupped” refers the concave edge or end surface of crooked lumber.

The term “flush line” refers to a true or plane surface along the framing lumber edge placed adjacent a wall.

The term “flush point” is the point along the cupped edge of crooked lumber where the edgewise deviation equals the gauge thickness of the metal shim.

The term “gap” refers to a space between the cupped edge of crooked lumber and any adjacent planer surface, for example a countertop.

In current framing practice, where electrical wiring and/or plumbing lines extend through framed walls, ceilings, floors, or the like, it is difficult to correct problems associated with crooked framing lumber. Such crooked framing members are not easily removed and replaced with non-warped straight framing because of the utility service lines. In such instances, for example, where the crown side of a crooked stud extends outside the flush line of a framed wall, and where it is necessary to have a true and plane wall surface, carpenters mark or draw a flush line along the crown side and saw away the protruding portion of the crown to provide a true or flush line surface for installing the finished wall. However, when the cupped edge of a crooked stud needs to be corrected to install a planer wall surface, it is very difficult and time consuming to remove the edgewise deviation. In most instances, the stud needs to be removed and it is replaced with a stud comprising pieced together sections that provide access for utility service lines.

Accordingly, it is a first object of the present invention to provide a shim device that corrects edgewise deviation along the cupped edge of a crooked framing member.

It is another object of the present invention to provide a channel shaped metal shim that provides a flush line along the cupped edge of crooked framing.

It is a further object of the present invention to provide a channel shaped metal shim that does not interfere with or contact utility service lines that extend through crooked framing.

Specifically, this invention comprises a channel shaped metal shim for correcting edgewise deviation along the cupped edge of a crooked framing member, the channel shaped metal shim comprising a web extending between a first flange and a second flange. The web has a width ≧ the thickness of the cupped edge, and the first flange and said second flange each have a flange depth <½ the face depth of the crooked framing member so that the first flange and second flange can be fixed to the crooked framing member without contacting utility service extending through the crooked frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of crooked framing lumber.

FIG. 2 is an isometric view showing one embodiment of the present channel shaped metal shim capable of correcting cupped edge deviation in crooked framing lumber.

FIG. 3 is an isometric view showing another embodiment of the present channel shaped metal shim capable of correcting cupped edge deviation in crooked framing lumber.

FIG. 4 is an elevation view of a crooked stud in a framed wall.

FIG. 5 is an enlarged elevation view of the stud in FIG. 4 showing a gap between the cupped edge and a flush line.

FIG. 6 is an enlarged elevation view of the stud in FIG. 4 showing a top flush point.

FIG. 7 is an enlarged elevation view of the stud in FIG. 4 showing a bottom flush point.

FIG. 8 is an elevation view of the stud in FIG. 4 showing the present channel shaped metal shim fixed between the flush points to correct cupped edgewise deviation.

FIG. 9 is an elevation view showing the present channel shaped metal shim fixed to a rafter to correct cupped edge deviation.

FIG. 10 is an elevation view showing the present channel shaped metal shim fixed to a joist to correct cupped edge deviation.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, FIG. 1 shows an exemplary crooked framing member 1 having an edgewise deviation 2 measured from a straight line 3 drawn along the crown edge 4 from one end 5 to an opposite end 6 of the framing lumber, and an edgewise deviation 7 measured from a straight line 8 drawn along the cupped edge 9 from each end 5 and 6 of the framing lumber. A utility service line aperture 10 was provided before warping caused the lumber to crook. As heretofore mentioned above, when utility service lines extend through aperture 10, it is extremely difficult and labor intensive to correct deviation along the cupped edge of such crooked framing lumber.

Referring to FIG. 2, one embodiment of the present channel shaped metal shim 11 comprises a web 12 extending between a first flange 13 and a second flange 14. A plurality of spaced apart fastening apertures 15 may be provided along the length of shim 11. Apertures 15 facilitate fixing flanges 13 and 14 to each face 16 (FIG. 1) along the cupped edge of crooked framing lumber. Web 12 has an inside width “W”≧the cupped edge thickness of typical framing lumber used in residential construction, i.e. 1½ inches or larger. The inside web width “W” enables the flanges 13 and 14 to clasp the face portions 16 when shim 11 is placed over the cupped edge of lumber to correct deviation as shown in FIG. 8. The depth “D” of flanges 13 and 14, measured from web 12, is <½ of the depth of the framing lumber face 16 so that there is no flange contact with utility service lines that extend through any apertures 10 provided along the length framing lumber. A preferred flange depth “D” is about 1¾ inches deep to avoid flange/utility line contact when shim 11 is used to correct cupped edgewise deviation in 2×4 framing lumber and larger.

In an alternant embodiment shown in FIG. 3, the channel shaped metal shim 11 a has the same inside web width “W” and flange depth “D” as shown and described in FIG. 2. In this embodiment, shim 11 a includes a plurality of spaced fastener tabs 17 that extend along the length of the shim flanges 13 a and 14 a. Fastener tabs 17 are substantially triangular shaped and extend outboard from punched openings 18 along flanges 13 a and 14 a so that their pointed tip ends 19 can be driven through openings 18 and into each face 16 to fix shim 11 a to the cupped edge of crooked framing lumber.

Referring now to FIGS. 4 and 5, in a typical residential framing system for a wall, wooden studs 20, either a 2×4 or a 2×6 lumber, extend between a bottom sill plate 21, and a top sill plate 22. When framing is not crooked, the straight studs 20 follow a flush line 23 that that defines the true or plane surface of an adjacent wall. Such straight framing will provide a substantially true and planer wall surface that is easy to work with and provides a high quality appearance when cabinets, countertops, backsplashes, appliances, tile, and the like are placed against the wall surface. In contrast, when warping causes studs to crook, the studs are replaced to provide a flush line surface. However, in studs that contain utility service lines 24, they are usually not replaced and deviation is only corrected along the crown edge 25. Such crown edge correction is done by sawing as disclosed above, and deviation is usually not corrected along the cupped edge 26. Referring in particular to FIG. 5, when drywall 27 is installed along such uncorrected framing, it does not provide a true and planer wall surface and the uneven wall surface causes a gap “G” between the wall and any finish work 28 placed against the uneven wall. Most builders fill the gap with caulk, and if necessary, add quarter round trim or the like to cover the gap. Such patch-up work adds time and material cost to the job and is considered shoddy work by high quality builders as well as potential buyers.

Referring to FIGS. 6, 7, and 8, showing the same crooked stud 20 in FIGS. 4 and 5, the present channel shaped metal shim invention simplifies deviation correction along the cupped edge of crooked framing lumber that contains utility service lines, and it eliminates the need for shoddy patch-up efforts along gaps formed between the wall and adjacent finish work. A first flush point 30 a is determined and marked, where a flush point gap 7 a measured from flush line 23 to the cupped edge 26 is equal to the gauge thickness of the metal used to manufacture the metal shim 11 or 11 a disclosed in FIGS. 2 and 3. In a similar manner, a second flush point 30 b is determined and marked where a flush point gap 7 b is equal to the shim metal gauge thickness. A deviation length 31 between the two flush points 30 a and 30 b is measured and a metal shim 11 or 11 a is trimmed along its length to correspond with the length 31. However, it should be understood that metal shim 11 or 11 a can be trimmed to less than the deviation length 31 without departing from the scope of the present invention. Web 12 of the channel shaped metal shim is placed against the cup edge 26 of the crooked stud 20 so that the flanges clasp each face 36 of the crooked stud without contacting utility service lines 24 contained within the framed wall, and the metal shim is fixed to stud 20. The flanges are fixed to the stud by either driving fasteners through flanges 13 and 14 (FIG. 2) into each face 16, or by driving the punched tabs 17 on flanges 13 a and 14 a (FIG. 3) into each face 16.

FIG. 9 shows the present channel shaped metal shim, either 11 or 11 a fixed to the cup edge 46 of a crooked rafter 39 to correct edgewise deviation. Similar to the crooked stud shown in FIGS. 6, 7, and 8, the metal shim is fixed to the rafter between two flush points 40 a and 40 b, with the shim web adjacent the flush line 43 and the flanges clasping each face 47 of the crooked rafter without contacting utility service lines 24.

FIG. 10 shows the present channel shaped metal shim, either 11 or 11 a fixed to the cup edge 56 of a crooked floor joist 49 to correct edgewise deviation. Similar to the crooked rafter in FIG. 9, the metal shim is fixed to the floor joist between two flush points 50 a and 50 b, with the shim web adjacent the flush line 53 and the flanges clasping each face 57 of the crooked joist without contacting utility service lines 24. Cup edge deviation in a ceiling joist is corrected in the same manner as a floor joist, however, in a ceiling joist the cup edge and channel shaped metal shim extend along the bottom or opposite edge as compared to the floor joist shown in FIG. 10.

As such, an invention has been disclosed in terms of preferred embodiments and alternate embodiments thereof, which fulfills each one of the objects of the present invention as set forth above and provides a channel shaped metal shim capable of correcting edgewise deviation in a crooked framing member. Of course, various changes, modifications, and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims. 

1. A, channel shaped metal shim for correcting edgewise deviation along a cupped edge in crooked framing members, the metal shim comprising: a web having a width ≧ a thickness of the cupped edge, and a first flange and second flange, each flange having a flange depth <½ a face depth of the crooked framing members so that said first flange and said second flange can be fixed to crooked framing members without contacting utility service extending through the framing member.
 2. The metal shim recited in claim 1, comprising a length equal to a deviation length of a crooked wood framing member.
 3. The metal shim recited in claim 1, comprising a flange depth of about 1¾ inches.
 4. The metal shim recited in claim 1, comprising a web width of about 1½ inches.
 5. A combination channel shaped metal shim and warped wood framing member, comprising: a) a crooked wood framing member that has cupped edge deviation from a flush line along a wood framed wall; and b) a channel shaped metal shim having a first flange and a second flange fixed to the crooked wood framing member between a first flush point gap and a second flush point gap that define a deviation length along the crooked wood framing member, and a web that extends outward from a cupped edge of the crooked wood framing member to a positioned adjacent said flush line so that cupped edge deviation is corrected along said deviation length, said wed having a width≧a thickness of the crooked wood framing member, said first flange and said second flange each having a flange depth <½ a depth of the crooked wood framing member so that said first flange and said second flange are fixed to the wood framing member without contacting utility service extending therethrough.
 6. The metal shim recited in claim 5, comprising a length equal to said deviation length between the first flush point gap and the second flush point gap of the framing member.
 7. The metal shim recited in claim 5, comprising a flange depth of about 1¾ inches.
 8. The metal shim recited in claim 5, comprising a web width of about 1½ inches.
 9. The metal shim recited in claim 5, comprising a crooked wood stud.
 10. The metal shim recited in claim 5, comprising a crooked wood joist.
 11. The metal shim recited in claim 5, comprising a crooked wood rafter.
 12. A method for correcting edgewise deviation in a crooked wood framing member using a channel shaped metal shim, the steps of the method comprising: a) determining the location of a first flush point along a length of the crooked wood framing member where a gap between a cupped edge of the framing member and a flush line of a wood framed wall is substantially equal to a gauge thickness of the metal shim; b) determining the location of a second flush point along the length of the crooked wood framing member where a gap between the cupped edge and the flush line is substantially equal to the gauge thickness of the metal shim; c) positioning a web portion of a channel shaped metal shim between said first flush point and said second flush point and adjacent the flush line, the positioned web correcting edgewise deviation along a deviation length of the crooked wood framing member; and d) fixing a first flange and a said second flange of the channel shaped metal shim to the crooked wood framing member, each flange having a depth <½ a depth of the crooked wood framing member so that said first flange and said second flange do not contact utility service extending therethrough.
 13. The method recited in claim 12, comprising a channel shaped metal shim having a length equal to said deviation length between the first slush point and the second flush point.
 14. The method recited in claim 12, comprising a channel shaped metal shim having a flange depth of about 1¾ inches.
 15. The method recited in claim 12, comprising a channel shaped metal shim having a web width of about 1½ inches.
 16. The metal shim recited in claim 5, comprising a crooked wood stud.
 17. The metal shim recited in claim 5, comprising a crooked wood joist.
 18. The metal shim recited in claim 5, comprising a crooked wood rafter. 